Method of manufacturing a package and packaging machine

ABSTRACT

A packaging machine and a method of manufacturing a package are provided. The method may comprise the following: forming a container ( 13 ) in a web of a first web-like material ( 7 ) by deep-drawing; forming a lid ( 14 ′) in a web of a further web-like material ( 9 ′) by deep-drawing; placing the lid ( 14 ′) onto the container ( 13 ); and subsequently separating the container ( 13 ) from the first web-like material ( 7, 9 ′), wherein an edge ( 20, 21, 22 ) of the container ( 13 ) and an edge ( 20′, 21′, 22 ′) of the lid ( 14 ′) are formed in an angled or bent form.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims foreign priority benefits under 35 U.S.C. §119(a)-(d) to German patent application number DE 102009015343.8, filed Mar. 27, 2009, which is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

The present invention relates to a method of manufacturing a package and to a packaging machine.

BACKGROUND

For commercializing goods, such as e.g. food, these are often packed into packages that permit a hygienic and optically attractive presentation.

From DE 10 2006 017 258 A1, a method of manufacturing a package is known in which a container is formed in a web of a first web-like material, subsequently a lid is sealed onto the produced container within an outer contour of the package to be produced, and the container is separated from the first web-like material along the outer contour of the package to be produced and outside the lid that was sealed on.

Furthermore, packages are known which comprise a so-called rolled edge and are usually sealed on a tray sealing machine after they have been filled. That means, already finished trays are filled and subsequently sealed. Moreover, such packages are often provided with a slip lid which is also produced outside the tray sealing machine and which is to ensure that the packages can be reclosed after the sealed foil has been opened. Conventional slip lids, however, only have a very loose seat, so that already during the transport of the package, the slid lid often detaches itself from the package. For the consumer, too, the loose seat of the slip lid is disadvantageous and annoying when the package is handled.

SUMMARY

It is an object of the present invention to provide an improved method of manufacturing a package as well as an improved packaging machine which may permit to produce packages that meet the highest demands on manageability and visual appearance and can moreover be manufactured in an inexpensive manner.

The object may be achieved by a method according to claim 1 as well as by a packaging machine according to claim 10. Further developments of the invention are given in the respective sub-claims.

With the method according to the invention and the packaging machine according to the invention, packages can be produced which are easily manageable thanks to the stable seat of the slip lids on the containers and comprise an optically attractive shape. Advantageously, the slip lid may be connected to the bottom film, that means to the previously deep-drawn container, by several sealing points or strips, respectively, to prevent the slip lid from detaching itself during transport. These comparatively small seal areas can be easily removed or broken open by the consumer. The knobs according to the invention, which are provided at the slip lid as well as at the container, moreover ensure a secure and accurate reclosability of the package.

A further advantage of the method according to the invention or the packaging machine, respectively, is that the slip lid is cost-effectively produced and placed on directly by means of the packaging machine. Thus, no further machine that produces and places on the slip lid is required. Moreover, the interface and transfer problems of produced packages and/or lids to other packaging machines that occur in conventional methods are eliminated here.

Furthermore, there is an advantage in that, compared to devices and methods where lids are sealed onto prefabricated package trays or containers, respectively, an exact positioning and grouping of the containers is not necessary as the position of the containers is monitored over the complete processing path. Thereby, the packages can be inexpensively produced in a small space.

The packages are separated into singles only at the end of the packaging process, and reliable transport is ensured during the packaging process. The packages can be separated from the web-like material accurately and close to a given, individually shaped outer contour, whereby optically attractive and mechanically stable packages can be produced.

Further features and expediencies of the invention can be taken from the description of embodiments with reference to the enclosed drawings. In the Figures:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a schematic side view of a packaging machine;

FIG. 2 a shows a schematic perspective view of a container produced in accordance with the method according to the invention;

FIG. 2 b shows a schematic perspective view of the container with a first lid;

FIG. 2 c shows a schematic perspective view of the container with the first lid and a second lid;

FIG. 3 a shows a schematic partial view of the edge region of the container and the first and second lids in a first embodiment;

FIG. 3 b shows a schematic partial view of the edge region of the container and the first and second lids in a second embodiment; and

FIG. 4 shows a schematic plan view of a cutting station.

DETAILED DESCRIPTION

Below, a first embodiment of the present invention will be first described with reference to the enclosed figures.

FIG. 1 shows the schematic side view of a packaging machine 100.

The packaging machine 100 comprises a first forming station 1, a first sealing station 2, a second forming station 1′, a second sealing station 2′, a cross cutter 3 and a longitudinal cutter 4 which are in this sequence arranged at a machine frame 5 in a direction of transport R. At the entry side, a first feed roller 6 is disposed at the machine frame 5 from which roller a first web-like material 7 or a first foil is reeled off. A second feed roller 8 is provided from which a second web-like material 9 or a second foil, respectively, is reeled off. Furthermore, a third feed roller 8′ is provided from which a third web-like material 9′ or a third foil, respectively, is reeled off. Downstream of the first sealing station 2, a first discharge means 10 in the form of a roller is provided onto which a residual foil skeleton 90 of the second web-like material 9 is reeled which remains after the first sealing station 2.

In the region of the first sealing station 2, a first transport means 11 is furthermore provided by which the second web-like material 9 is, in a main cycle, transported into the first sealing station 2, cut there and the residual foil skeleton 90 is transported out of the first sealing station 2. In the region of the second sealing station 2′, a second transport means 11′ is provided by which the third web-like material 9′ is transported into the second sealing station 2′ in a main cycle. Both transport means 11, 11′ can be realized, for example, by laterally arranged chains or grippers or by friction rollers. On the exit side, a second discharge means 12 is provided in the form of a conveying belt at the packaging machine 100, by means of which finished, separated packages are carried away. Furthermore, the packaging machine 100 comprises a non-depicted feed means which laterally grips the first web-like material 7 and intermittently transports it further into the direction of transport R in the main cycle. The (non-depicted) feed means can be realized e.g. by laterally arranged conveyor chains, lateral grippers or functional rollers.

In the shown embodiment, the first forming station 1 and the second forming station 1′ are embodied as deep-drawing stations in which containers 13 are formed in the first web-like material 7 in the first forming station 1 by deep-drawing and second lids 14′ are formed in the third web-like material 9′ in the second forming station 1′ by deep-drawing. The edge of the container 13 is here embodied as so-called rolled edge, that means in a shape angled or bent upwards or above the foil plane of the first web-like material 7. In the present case, the rolled edge is bent outwards and towards the container bottom. In this case, the first forming station 1 and the second forming station 1′, respectively, can be designed such that several containers 13 are formed next to each other in the direction perpendicular to the direction of transport R, that means in FIG. 1 into the plane of projection or out of it, respectively. In the direction of transport R after the first forming station 1, a non-depicted filling station is provided in which the containers 13 formed in the first web-like material 7 are filled for example with fruit or vegetables.

In the shown embodiment, the first sealing station 2 is embodied as combined sealing and lid cutting station. The first sealing station 2 is embodied such that first lids 14 are cut out of the second web-like material 9 and sealed onto a surrounding upper edge of the containers 13. It is also conceivable to supply already formed and/or cut first lids 14. The second sealing station 2′ is embodied such that second lids 14′ are placed onto the containers 13 together with the surrounding third web-like material 9′ by an integrated (non-depicted) placing-on station. In the present embodiment, the first, the second and the third web-like materials 7, 9, 9′ are each formed by plastic foils. The sealing stations 2, 2′ are furthermore embodied as closed chambers in a known manner in which the atmosphere in the containers 13 is replaced by a replacement gas, such as e.g. CO₂ as inert gas.

The cross cutter 3 is embodied as a punching machine which divides the first web-like material 7 between adjacent containers 13 together with the third web-like material 9′ in a direction transverse to the direction of transport R. In the process, the cross cutter 3 operates such that the first web-like material 7 is not cut across the total web width, but is not cut in two at least in an edge region. Moreover, in the embodiment shown in FIG. 4, a region between the packages in the direction of transport R is not cut in two. This permits a controlled further transport by the (non-depicted) feed means.

The longitudinal cutter 4 is, for example, embodied as a cutter arrangement by means of which the first web-like material 7 is cut in two together with the third web-like material 9′ between adjacent containers 13 and at the lateral edge of the first web-like material 7, so that there are separated packages downstream of the longitudinal cutter 4 which are separated from the first web-like material 7 and the third web-like material 9′ (also see FIG. 4). As an alternative, the cutting means can also be omitted in the first sealing station 2, so that the first web-like material 7, the second web-like material 9, and the third web-like material 9′ are simultaneously cut in two in the cross cutter 3 and the longitudinal cutter 4. Moreover, instead of the cross and longitudinal cutting, complete cutting can also be performed.

FIG. 2 a) shows the container 13 in a schematic perspective view. The first forming station 1 is embodied such that ribbings can be formed in the walls of the container 13 and beads or a relief in the bottom of the container 13 to increase the stability of the container 13. The ribbings in this case extend on each of the four side walls of the container 13 from the container bottom to the container edge. The beads are formed by individual quadrangular recesses essentially having the shape of a slice of cake which are formed into the container bottom and as a whole form an oval shape. The upper edge of the container 13 is essentially formed by a surrounding, horizontal first edge section 20, a following essentially vertical and also surrounding second edge section 21, and an essentially horizontal, also surrounding third edge section 22. These three edge sections 20, 21, 22 form a rolled edge of the container 13. In the second edge section 21, first projections 16 or first knobs 16, respectively, are formed.

FIG. 2 b) shows, in addition to the container 13, the first lid 14 which is sealed onto the containers 13 after they have been filled. It is also conceivable to treat the package or the product, respectively, with gas before it is sealed to increase its shelf life.

FIG. 2 c) shows the container 13, the first lid 14 and the second lid 14′. The edge of the second lid 14′ is formed corresponding to the edge contour of the container 13. First, an essentially horizontal first edge section 20′ is provided which is followed by an essentially vertical second edge section 21′ and which in turn is followed by an essentially horizontal third edge section 22′ extending in the plane of the originally web-like material 9′ of the second lid 14′. Second projections 17 or second knobs 17, respectively, are formed into the second edge section 21′. It is also conceivable to form a further recess open to the outside into the second lid 14′ into which for example a fork or salad dressing can then be placed. These would then be fixed e.g. by sticking on a label.

The first knobs 16 and the second knobs 17 cooperate when the second lid 14′ is placed onto the container 13 and clamp the second lid 14′ onto the container 13. This ensures a secure and accurate reclosability of the container 13.

FIG. 3 a) shows the connection of the slip lid 14′ with the container 13. The first and second knobs 16, 17 are engaged. Thanks to the plastic material of the container 13 and the second lid 14′, the second lid 14′ can also be easily removed. The first knobs 16 and the second knobs 17 are directed inwards.

FIG. 3 b) shows a second embodiment of the present invention. The first knobs 16 and the second knobs 17 are directed outwards. This is realized by a projection of the container 13 and of the second lid 14′ extending upwards in FIG. 3 a).

FIG. 4 shows the cross cutter 3 and the longitudinal cutter 4. The arrow shows the direction of transport R of the packages. Furthermore, the sealing strips by means of which the second lid 14′ or the slip lid 14′ is partially sealed onto the container 13 are shown (see FIGS. 1-2 c)). Apart from securing the second lid 14′ during transport to the end consumer, they also serve as evidence of genuineness.

The operating process of the above-described packaging machine 100 will be described in the following.

The first web-like material 7 is reeled off from the feed roller 6 and transported into the first forming station 1 by the (non-depicted) feed means. In the first forming station 1, the containers 13 are formed in the first web-like material 7 by deep-drawing. In the process, the containers 13 are, as shown in FIGS. 2 a)-c), formed such that they comprise the horizontal first edge section 20 in their surrounding edge region, which is followed at the outside by the angled or bent second edge section 21 in the circumferential direction, which essentially extends vertically, as is represented in FIGS. 2 a)-c). The third edge section 22 essentially extending horizontally follows in turn the second vertical edge section 21. All three edge sections 20, 21, 22 are each formed around the complete container 13.

The formed containers 13 are, in a main cycle, transported further to the (non-depicted) filling station together with the surrounding material of the first web-like material 7, where they are filled with the goods to be packed.

Subsequently, the filled containers 13 are, in the main cycle, transported further into the first sealing station 2 together with the material of the first web-like material 7 surrounding them by the (non-depicted) feed means. In synchronization with the feed of the filled containers 13, the second web-like material 9 is, in the main cycle, actively transported into the first sealing station 2 by the transport means 11. There, the lids 14 are cut out of the second web-like material 9 with a punching machine and sealed with application of heat between a sealing upper part and a sealing lower part with the material of the containers 13. The first lids 14 are cut out of the second web-like material 9 such that their outer contour extends within the outer contour of the containers 13 defined by the second edge section 21 and the horizontal section 22 (see FIG. 2 a)). The residual skeleton 90 of the second web-like material 9 remaining after the first lids 14 have been cut out is reeled onto the discharge roller 10 at the exit side of the first sealing station 2, so that it can be disposed of or recycled, respectively.

The now sealed or also filled and gassed containers 13 are transported further into the second 2′ sealing means with the (non-depicted) feed means of the first web-like material 7.

The third web-like material 9′ is reeled off from the third feed roller 8′ and transported into the second forming station 1′ by a further (non-depicted) feed means. In the forming station 1′, second lids 14′ are formed in the third web-like material 9′ by deep-drawing. The second lids 14′ are in the process formed in the shape which is shown in FIG. 2 c), such that their edge sections 20′, 21′, 22′ correspond to the edge sections 20, 21, 22 of the container 13.

The formed second lids 14′ are, in a main cycle, transported further into the second sealing station 2′ together with the surrounding material of the third web-like material 9′ by means of the second transport means 11′, where they are placed onto the containers 13 by means of the placing-on means. Moreover, the second lids 14′ are cut out of the third web-like material 9′ with a punching machine before, during or after they are placed on, and partially sealed with the second web-like material 9 between a sealing upper part and a sealing lower part in the form of sealing strips with application of heat (see FIG. 4). By this, the slip lid 14′ remains secured on the container 13 even during transport. A consumer can easily break open the not continuous sealing strips.

After the second sealing station 2′, the sealed containers 13 provided with the second lids 14′ as well as with the surrounding third web-like material 9′ are transported further into the cross cutter 3 by the (non-depicted) feed means of the first web-like material 7, where the first web-like material 7 is cut in two between the containers in the direction perpendicular to the direction of transport R (also see FIG. 4).

After cross cutting has been performed and rounded corners have been possibly formed, the containers 13 with the first web-like material 7 not yet cut in the direction of transport R are transported further to the longitudinal cutter 4 together with the third web-like material 9′. In the longitudinal cutter 4, the first web-like material 7 is cut along the outer contour of the containers 13 together with the third web-like material 9′ in the direction of transport R, that means in the longitudinal direction. The containers 13 and the second lids 14′, respectively, are now completely cut out of the first web-like material 7 and the third web-like material 9′ and are carried away as separated packages by means of the third discharge means 12.

With the described packaging machine 100 and the described method, the packages shown in FIG. 2 a) to FIG. 3 a) can be manufactured. As can be seen in FIGS. 2 a) to 2 c), the produced package comprises an optically attractive second edge section 21 angled or rounded towards the bottom.

The described packaging machine 100 permits to manufacture optically attractive packages with angled or bent around edges on a deep-drawing machine, where the containers 13, the first lids 14 as well as the second lids 14′ can be fabricated and sealed to each other within a short working path. Furthermore, the control of the containers 13 is not abandoned during the complete process as these are guided along with the first web-like material 7 until the last procedure step. Thus, on a cost-saving deep-drawing machine, packages can be efficiently manufactured with designs that up to now could only be produced with more complex and expensive processes.

The transport of the second and the third web-like material 9, 9′ by means of the transport means 11, 11′ has the advantage that the feed of the second and third web-like materials 9, 9′ over the containers 13 can be accurate and the remaining residual foil skeleton 90 can be reliably carried away out of the first sealing station 2.

Modifications of the described embodiment are possible. For example, the cross cutter 3 and the longitudinal cutter 4 can be combined to form one single cutting station where the containers 13 are cut, together with the second lids 14′, out of the first web-like material 7 and out of the third web-like material 9′, respectively, all around along their outer contours, e.g. with a punching machine.

In one operating cycle, several packages can also be processed one next to the other and after the other in the direction of transport R.

It is also conceivable that the second web-like material is a so-called skin foil which is not cut in the first sealing station but transported further with the first web-like material. Cutting can also be accomplished outside the package or at the edge of the package. The so-called skin foil is thin and lies against the product to be packed and also against the slip lid or the knobs for reclosing.

It is furthermore conceivable that there is no second web-like material and the slip lid is not only adhered to the container by a point seal, but that it is sealed all around to seal the package. The slip lid can be used as reclosable lid.

While exemplary embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention. 

1. A method of manufacturing a package, the method comprising: forming a container in a web of a first web-like material by deep-drawing; forming a lid in a web of a further web-like material by deep-drawing; placing the lid onto the container; and subsequently separating the container from the first web-like material; wherein an edge of the container and an edge of the lid are formed in a shape angled or bent upwards with respect to a plane defined by the respective web-like material.
 2. The method according to claim 1 wherein the edge of the container is formed such that the edge of the container corresponds to the edge of the lid and can receive the lid.
 3. The method according to claim 1 wherein the lid is a second lid and the further web-like material is a third web-like material, and wherein the method further comprises forming a first lid in a second web-like material and sealing the first lid onto the container.
 4. The method according to claim 3 wherein for reclosability of the container, the container is formed with first projections and the second lid is formed with second projections, wherein the first and second projections are both formed to be directed inwards or both formed to be directed outwards with respect to the container.
 5. The method according to claim 3 wherein the second lid is at least partially sealed onto the container.
 6. The method according to claim 3 wherein the first lid is cut to size prior to sealing the first lid onto the container and/or the second lid is cut to size prior to being placed on the container.
 7. The method according to claim 3 further comprising separating the first lid from the second web-like material and/or separating the second lid from the third web-like material after the second lid has been placed on the container.
 8. A packaging machine for producing packages, the packaging machine comprising: a first forming station for forming containers in a first web-like material by deep-drawing such that each container has an edge that is formed in a shape angled or bend upwards with respect to a plane defined by the first web-like material; a second forming station for forming lids in a further web-like material by deep-drawing such that each lid has an edge that is formed in a shape angled or bend upwards with respect to a plane defined by the further web-like material; a placing-on station for placing the lids onto the containers; and a cutting station which is designed such that the containers can be separated from the first web-like material along the outer contour of each package to be produced.
 9. The packaging machine according to claim 8 further comprising a first sealing station and a second sealing station.
 10. The packaging machine according to claim 9 wherein the lids are second lids and the further web-like material is a third web-like material, and wherein the first sealing station is configured to seal first lids from a second web-like material onto the containers.
 11. The packaging machine according to claim 10 further comprising a lid cutting station for cutting out the first lids from the second web-like material such that a respective first lid is cut out from the second web-like material before sealing the respective first lid onto a respective container.
 12. The packaging machine according to claim 10 wherein the first forming station is configured to form first projections in each container, and the second forming station is configured to form second projections in each second lid, the first and second projections being designed to provide reclosability of the packages, and wherein for each package, the first and second projections are directed inwards or outwards.
 13. The packaging machine according to claim 10 wherein the placing-on station is designed to cut out the second lids from the third web-like material such that a respective second lid is cut out from the third web-like material before placing the respective second lid on a respective container.
 14. The packaging machine according to claim 10 further comprising a discharge device provided downstream of the first sealing station for receiving a remaining residual skeleton of the second and/or third web-like material.
 15. The packaging machine of claim 10 wherein the second sealing station is located downstream of the first sealing station, and the second sealing station is configured to at least partially seal each second lid onto a respective container. 